Roofing, cladding or siding product, its manufacture and its use as part of a solar energy recovery system

ABSTRACT

This disclosure provides a roofing, cladding or siding product which is light weight, easy to install, durable and resistant to environmental wear. One embodiment relates to a module that can be used to form a weatherproof covering over top of a building surface. Another embodiment is a module which can, in additional to forming a weatherproof covering, be used as part of a thermal energy recovery or removal system. Yet another embodiment is a module which can, in addition to forming a weatherproof covering, and optionally in addition to being useful as part of a thermal energy recovery system, bears an array of solar cells to generate electrical energy. Assemblies, systems, uses, and methods of manufacture are also described.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to international patentapplication number PCT/NZ2012/000221, having a filing date of Nov. 30,2012, which claims the benefit of priority to New Zealand patentapplication number NZ 596793, having a filing date of Nov. 30, 2011, thecomplete disclosures of which are hereby incorporated by reference forall purposes.

TECHNICAL FIELD

The present technology relates generally to the manufacture of roofing,cladding and/or siding products, and to systems, assemblies, methods anduses for such a product, including the collection of solar and/orthermal energy.

BACKGROUND

The following description is provided to assist the understanding of thereader. None of the information provided or references cited is admittedto be prior art to the present invention.

Environmental and sustainability concerns have created a need foralternative or renewable energy systems. Solar energy is one type ofrenewable energy source, and the sun's energy can be collected in avariety of different ways. One is converting solar energy into thermalenergy to heat a fluid, such as air or water. Another is convertingsolar energy to electricity using photovoltaic cells. A properly sizedand installed solar energy collection system can be a practicalalternative for acquiring energy needs.

The disadvantages of traditional products for these purposes are thatthey are heavy and difficult to install, many do not have gooddurability and environmental resistance, and many are difficult to massproduce economically. Such roofing and cladding surfaces tend to heat upover periods of exposure to sunlight, and the heat may then betransferred to the interior of the building. This can increase theexpense of air conditioning and environmental control. Therefore,various methods of deflecting the heat, for example by providingreflective surfaces, are also known.

In some cases, exposure to sunlight can be beneficial because of thepossibility of being able to photovoltaically generate electrical power.Generally, the collection of any significant amount of solar energyrequires a large area of photovoltaic surface be exposed to unobscuredsunlight. It is well known in the art that building roof tops andexterior wall cladding provide vast areas of unoccupied space where itis convenient and effective to position such photovoltaic surfaces. Aseries of photovoltaic panels may be mounted on a roof to generateelectrical energy. This energy can be used as generated (wholly or inpart), be stored wholly or in part (e.g. to batteries) and/or beconverted to AC and be fed wholly or in part into the grid. An advantagein improved aesthetics, less weight, less panel materials and lessexposure to wind can be achieved when such PV panels are integrated intothe building cladding products. This can also reduce the total materialand installation costs associated with a solar electricity system.

However, PV roofing and cladding products can be complex and costly toproduce, especially in 3D polymer form and in large scale production.They can also lack durability, aesthetics and weather resistance thatwould otherwise be desirable in a roofing product. In terms ofdurability, many conventional PV roofing and cladding products areinherently unstable when exposed to sunlight for an extended period oftime. Moreover, prior art photovoltaic roofing shingles are generallydifficult to install. These products typically come as single tiles orshingles. Numerous tiles or shingles are required in an array to provideroof cladding. Such small tiles or shingles require electrical junctionsbetween each of the photovoltaic cells. Such junctions can be timeconsuming to connect and are often a failure point of the productbecause they corrode or the connections are incorrectly made. A furtherdifficulty is that some of the energy from the solar cells will simplybe dissipated as heat. The hotter the cells get, the less efficientlythey work, and the higher the heat transmission through the roof surfaceinto the building. Because roofing tiles are often designed to insulatethe rest of the house from getting too hot, they also tend to preventthe solar cells from cooling effectively.

Therefore, a need exists for thermal and/or photovoltaic roofing systemsthat are easy to manufacture, effectively utilize the sun's energy, areweatherproof, durable, aesthetically pleasing, and economical.

It is therefore an object of the present invention to provide a forthermal and/or photovoltaic roofing product and/or system which will goat least some way towards addressing the foregoing problems or whichwill at least provide the public with a useful choice.

In this specification where reference has been made to patentspecifications, other external documents, or other sources ofinformation, this is generally for the purpose of providing a contextfor discussing the features of the invention. Unless specifically statedotherwise, reference to such external documents is not to be construedas an admission that such documents, or such sources of information, inany jurisdiction, are prior art, or form part of the common generalknowledge in the art.

Further aspects and advantages of the present invention will becomeapparent from the ensuing description which is given by way of exampleonly.

SUMMARY OF INVENTION

In various aspects, the present invention provides a roofing, claddingor siding product which is light weight, easy to install, weatherproof,durable, resistant to environmental wear, and aesthetically pleasing.One embodiment relates to a module that can be used to form aweatherproof covering over top of a building surface. Another embodimentis a module which can, in additional to forming a weatherproof covering,be used as part of a thermal energy recovery or removal system. Yetanother embodiment is a module which can, in addition to forming aweatherproof covering, and optionally in addition to being useful aspart of a thermal energy recovery or removal system, bears an array ofsolar cells to generate electrical energy.

In a first aspect, the present invention provides a roofing, cladding,or siding module comprising a plurality of formed surfaces moulded fromone or more polymeric materials, wherein each of the formed surfacescomprise three dimensional surface features, and wherein the formedsurfaces are joined (i.e., integrated together, juxtaposed, or united)without weld lines or injection moulding points.

In one embodiment, each formed surface is a moulded segment along thelength of the module. In one embodiment, the three dimensional surfacefeatures of each of the formed surfaces are the same or different. Inone embodiment, the three dimensional surface features have the same orvariable thickness. In one embodiment, the module is substantially flat.In one embodiment, each formed surface comprises an underlapping regionand an exposed region, wherein the underlapping region is adapted to besubstantially covered by the exposed region of an adjacent module wheninstalled on a building surface.

In one embodiment, the roofing, cladding, or siding module comprises aplurality of formed surfaces moulded from one or more polymericmaterials, wherein each of the formed surfaces comprise threedimensional surface features, and wherein the formed surfaces aresequentially formed in a continuum. In some embodiments, the module isformed as it runs through a continuous forming process (as opposed to adie stamping or injection moulding process). Thus, the formed surfaceswith the three dimensional surface features are sequentially formed inthe continuous forming process.

In a second aspect, the present invention provides a roofing, cladding,or siding module comprising: an underlapping region and an exposedregion, wherein the underlapping region is adapted to be substantiallycovered by the exposed region of an adjacent module when installed on abuilding surface; and an outer surface and an under surface, wherein theunder surface of the underlapping region is profiled to define a pathwayfor air flow between the module and the building surface.

In one embodiment, the outer surface of the exposed region comprisessurface ornamentation. In one embodiment, the surface ornamentationresembles asphalt shingles, slate, wooden shakes, concrete tiles, or thelike.

In one embodiment, the outer surface of the exposed region comprises aphotovoltaic cell or device. In one embodiment, the module furthercomprises a solar radiation transmissible film which is overlaid uponthe photovoltaic cell.

In one embodiment, the profile of the underside of the underlappingsurface is patterned in a manner to (1) create turbulence in theairflow, (2) increase the surface area of the module in contact with thepassing airflow compared to a module lacking such a surface pattern, orboth (1) and (2). In one embodiment, the profile of the underside of theunderlapping region comprises a plurality of projections that create atortuous pathway above the actual or notional plane of the buildingsurface. In one embodiment, the profile of the underside of theunderlapping region comprises corrugated form of alternating parallelgrooves and ridges.

In one embodiment, the module is moulded from one or more polymericmaterials. In one embodiment, the one or more polymeric materials areselected from the group consisting of polycarbonate, foamedpolycarbonate, thermoplastic polyurethane (TPU), thermoplasticpolyolefin (TPO), polyvinyl chloride (PVC), aquilobutalstyrene (ABS),styrene-acrylonitrile resin (SAN), thermoplastic rubber, and any otheramorphous or crystalline polymer or combination of polymers. In oneembodiment, the one or more polymeric materials are flame retardant. Inone embodiment, the one or more polymeric materials are weather, hail,ultraviolet, tear, mold and impact resistant.

In one embodiment, the module comprises at least two layers of polymericmaterial, wherein the layers are of the same or different polymericmaterial. In one embodiment, at least one material has high UVresistance. In one embodiment, at least one material has high thermalconductivity. In one embodiment, the module further comprises areinforcement layer.

In one embodiment, the module or the polymer layers can be coloured orcomprise a blend of colours. In one embodiment, the polymer on the outerlayer of the module can be manufactured to mimic traditional roofingproducts. In one embodiment, the polymer on the outer layer of themodule can be coloured to contrast with the colour of the PV cell layerto define an aesthetic feature, e.g. shadows.

In one embodiment, the module comprises a first and a second polymericmaterial. In one embodiment, the first polymeric material has beenfoamed. In one embodiment, the first polymeric material is able tochemically bond with the second polymeric material. In one embodiment,the first polymeric material, the second polymeric material, or bothfurther comprise thermally conductive inclusions. In one embodiment, thethermally conductive inclusions have been blended and/or bonded to acompatible polymer or ionomer prior to mixing with the first polymericmaterial. In one embodiment, the thermally conductive inclusions arealuminum particles. In one embodiment, the second polymeric material canself seal to a penetrative fastener. In one embodiment, the firstmaterial is foamed polycarbonate and the second material isthermoplastic polyurethane.

In one embodiment, the top and bottom sides of the underlapping regioncontain complementary locating elements. In one embodiment, theunderlapping region is profiled to define one or more regions for fixingby a penetrative fastener. In one embodiment, the one or more regionsfor fixing by a penetrative fastener are adapted to receive a nail orscrew gun head to accurately locate the fixing.

In one embodiment, the module has a convex precamber configured to applya pre-load pressure to encourage the edges and bottom surface to contactfirmly onto an adjacent underlapping panel when installed on a building.In one embodiment, the upper surface of the underlapping region, thelower surface of the exposed region, or both, comprise a strip offlexible polymeric material configured to prevent water from penetratingbetween two overlapping modules.

In one embodiment, the module has one or more concertina-shaped featuresto accommodate thermal expansion and contraction between fixing points.

In one embodiment, the upper surface of the underlapping regioncomprises channels configured to receive wires of a photovoltaic array.In one embodiment, the upper surface of the underlapping regioncomprises markings to show the correct position of wires and junctionsfor a photovoltaic array. In one embodiment, the upper surface of theunderlapping region comprises pockets or channels configured to receiveprinted circuit boards (PCB), communication devices, junction boxes,wires, buses, components, cells, and/or diodes of a photovoltaic array.

In one embodiment, the module is manufactured by a continuous formingprocess. In one embodiment, the module is continuously formed into ahorizontal strip capable of extending substantially across an entiresection or width of the building surface to be covered. In oneembodiment, the module is continuously formed into a vertical stripcapable of extending substantially down an entire section or length ofthe building surface to be covered.

In a third aspect, the present invention provides a roofing, cladding,or siding assembly comprising a plurality of partially-overlappingmodules that substantially covers a building surface, wherein eachmodule comprises an underlapping region and an exposed region, whereinthe underlapping region is adapted to be substantially covered by theexposed region of an adjacent module when installed on a buildingsurface and the exposed region is adapted to be substantially exposedwhen installed on a building surface; an outer surface and an undersurface, wherein the under surface of the underlapping region isprofiled to define a pathway for air flow between the module and thebuilding surface.

In one embodiment, one or more of the modules comprises a photovoltaiccell or device. In one embodiment, the photovoltaic cell or devices areelectrically connected by continuous bus strips. In one embodiment, thecontinuous bus strips only require one terminating junction point to beconnected on installation. In one embodiment, the air flow between theunderlapping region and the building surface is induced by convection ora fan.

In one embodiment, the modules overlap down the fall of the buildingsurface. In one embodiment, the modules overlap across a buildingsurface. In one embodiment, each module is adapted to be fixablyattached to the building surface by at least one fastening member oradhesive. In one embodiment, at least one fastening member is a nail,staple or screw. In one embodiment, the roofing, cladding, or sidingassembly forms a weathertight seal over the building surface.

In a fourth aspect, the present invention provides a system for removingor recovering thermal energy from a building surface, the systemcomprising a building surface; a roofing, cladding, or siding assemblycomprising a plurality of partially-overlapping modules thatsubstantially covers the building surface, wherein each module comprisesan underlapping region and an exposed region, wherein the underlappingregion is adapted to be substantially covered by the exposed region ofan adjacent module when installed on a building surface and the exposedregion is adapted to be substantially exposed when installed on abuilding surface; an outer surface and an under surface, wherein theunder surface of the underlapping region is profiled to define a pathwayfor air flow between the module and the building surface; and a fanadapted to induce the air flow.

In one embodiment, the system further comprises a heat exchanger. In oneembodiment, the heat exchanger is part of an air conditioning system,water heating system, or air or media (e.g., sand, ground glass, orconcrete) heating system.

In a fifth aspect, the present invention provides a system forgenerating electricity and recovering or removing thermal energy from abuilding surface, the system comprising a building surface; a roofing,cladding, or siding assembly comprising a plurality ofpartially-overlapping modules that substantially covers the buildingsurface, wherein each module comprises an underlapping region and anexposed region, wherein the underlapping region is adapted to besubstantially covered by the exposed region of an adjacent module wheninstalled on a building surface; and an outer surface and an undersurface, wherein the under surface of the underlapping region isprofiled to define a pathway for air flow between the module and thebuilding surface, and wherein the outer surface of the exposed regioncomprises one or more photovoltaic cells.

In one embodiment, the system further comprises a vent for exhaustingthe air flow. In one embodiment, the system further comprises a heatexchanger adapted to receive the air flow. In one embodiment, the airflow is induced by a fan. In one embodiment, the speed of the fan isproportional to the energy created by one or more PV cells. In oneembodiment, the air flow is reversible in order to heat the roof toremove snow, ice, and/or moisture. In another embodiment, the air flowis able to move air from a warmer section of the roof to a coolersection of the roof. In one embodiment, the system is operable (a) togenerate electricity from the one or more photovoltaic cells and (b) toduct an induced or uninduced air flow to be heated and outputted to theheat exchanger during times of solar absorption or heat transmission bythe modules.

In a sixth aspect, the present invention provides a method for removingor recovering thermal energy from a building surface, the methodcomprising inducing an airflow to pass through an air passage between abuilding surface and an under surface of a plurality ofpartially-overlapping modules that substantially cover the buildingsurface; wherein each module comprises an underlapping region and anexposed region, wherein the underlapping region is adapted to besubstantially covered by the exposed region of an adjacent module wheninstalled on a building surface and the exposed region is adapted to besubstantially exposed when installed on a building surface; and an outersurface and an under surface, wherein the under surface of theunderlapping region is profiled to define a pathway for air flow betweenthe module and the building surface.

In one embodiment, the method further comprises venting the airflow tothe outside of the building. In one embodiment, the method furthercomprises collecting the thermal energy from the airflow after it passesthrough the air passage. In one embodiment, the collecting of thermalenergy is by placing the airflow in thermal contact with a cooler fluid.In one embodiment, the cooler fluid comprises part of an airconditioning or water heating system.

In a seventh aspect, the present invention provides a method forsimultaneously generating electricity and recovering thermal energy froma building surface, the method comprising inducing an airflow to passthrough an air passage between a building surface and an under surfaceof a plurality of partially-overlapping modules that substantially coverthe building surface; and collecting electrical energy from one or morephotovoltaic cells present on an exposed surface of the modules; whereineach module comprises an underlapping region and an exposed region,wherein the underlapping region is adapted to be substantially coveredby the exposed region of an adjacent module when installed on a buildingsurface and the exposed region is adapted to be substantially exposedwhen installed on a building surface; and an outer surface and an undersurface, wherein the under surface of the underlapping region isprofiled to define a pathway for air flow between the module and thebuilding surface.

In an eighth aspect, the present invention provides a method ofmanufacture of a roofing, cladding, or siding module, the methodcomprising: providing to a continuous forming machine a feed materialable to assume and retain a form after being moulded between a firstforming surface and a second forming surface; allowing the formation totake place as such surfaces are advanced in the same direction; whereinthe output is a roofing, cladding, or siding module comprising: anunderlapping region and an exposed region, wherein the underlappingregion is adapted to be substantially covered by the exposed region ofan adjacent module when installed on a building surface; and an outersurface and an under surface, wherein the under surface of theunderlapping region is profiled to define a pathway for air flow betweenthe module and the building surface.

In one embodiment, the feed material comprises a layer of a firstmaterial beneath a layer of a second material. In one embodiment, thefirst material is extruded to a supporting surface of a continuousforming machine, and the second material is extruded to the top surfaceof the feed of first material. In one embodiment, the exposed regioncomprises both materials, and the underlapping region comprises, atleast in part, only one of the materials. In one embodiment, the axis ofadvancement of the materials in the continuous forming machine iscommensurate with the longitudinal axis of the module as it lies withthe longitudinal axis across the fall of a roof to be clad thereby.

In one embodiment the entire roofing, cladding or siding module is madefrom a single material.

In one embodiment the module design features can be achieved bythermoforming, pressing, or other method of forming, either continuouslyor discontinuously wood, metal, concrete, resins, glass, clay,composites or the like.

In a ninth aspect, the present invention provides a method ofmanufacture of a roofing, cladding or siding module, the methodcomprising: providing a feed material in liquid or viscous form to amould in a moulding position; allowing the material to be moulded as asegment in the moulding position; advancing the moulded segment to aposition subsequent to, yet partially overlapping the moulding position;providing further material in liquid or viscous form to the mouldingposition; allowing the material to be moulded as a further segment inthe moulding position along with, or so as to adhere to, the overlappingsection of the previously moulded segment; wherein the output is aroofing, cladding, or siding module comprising: an underlapping regionand an exposed region, wherein the underlapping region is adapted to besubstantially covered by the exposed region of an adjacent module wheninstalled on a building surface; and an outer surface and an undersurface, wherein the under surface of the underlapping region isprofiled to define a pathway for air flow between the module and thebuilding surface.

In a further aspect, the invention provides a roofing, cladding, orsiding module having (i) a region to underlap a like or other module and(ii) a region to overlap a like or other module; wherein the overlapregion has on, or at least towards, its upper surface serially formedzones of three dimensional features, such zones being of polymericmaterial(s) provided as a continuum for that module's zones.

In some embodiments, the polymeric material is a layer over at least oneunderlying layer of polymeric material(s). One or other of the polymericmaterials may include a thermally conductive inclusion. In oneembodiment, each such zone of three dimensional features of an overlapregion and a corresponding part of an underlap region is formedsimultaneously. In one embodiment, the same polymeric material(s)provides each said zone and at least part of the underlap region.

In one embodiment, each region to underlap and each region to overlapare three dimensionally contoured. Such contouring can be through to theunder surface to provide for compatibility in overlap indexing. In oneembodiment, the overlap region on its upper surface is bothdimensionally contoured for aesthetic purposes and provided with zonesof features for solar related functionality purposes, e.g. features forassociation with photovoltaics. In one embodiment, such zones of threedimensional features are mutually juxtaposed or at least mutually close.

In a further aspect, the invention provides a building integrated solarenergy recovery system, the system comprising, including or using aroofing, cladding or siding of modules or the equivalent (“modules”)partially overlapping their adjacent modules down and/or across abuilding surface yet to collect in sunlight either, or both, (a) heatsolar energy as heat at least in part to pass to an underlying air flow,and/or (b) to generate electricity photovoltaically for outputting andconsequential heat at least in part to pass to said underlying air flow.In one embodiment, the modules, as installed on the building surface,with profile features of each module, provide an underlying pathway foran airflow to be heated by solar energy absorption and/or transmissionthrough said modules. In one embodiment, as part of the cladding array,photovoltaic devices or functionality included and/or carried by aregion or regions of any one or more module are not overlapped by anadjacent module.

In a further aspect, the invention provides the use of a buildingintegrated solar energy recovery system to either or simultaneously: (a)generate electricity from the photovoltaic array of shingles with aphotovoltaic functionality; and/or (b) duct heated air (e.g. for heattransfer purposes) from an induced or uninduced air flow under one ormore roofing, cladding or siding modules during times of solarabsorption and/or heat transmission by the modules.

In a further aspect, the invention provides a roofing, cladding orsiding component suitable or installed to pass solar energy received byat least some of its regions into an underlying airstream, and with aphotovoltaic regional functionality with a photovoltaic receiving regionto convert received solar energy into an electrical output. In oneembodiment, when as part or as part of a series down or across anunderlying building surface, is useable whereby each photovoltaicreceiving region is fully exposed despite partial overlapping of onecomponent to another to better shed water; and is useable whereby,despite attachment to the underlying building surface, there is a setoutfrom the underlying building surface sufficient to allow a passage of anunderlying airstream.

In some embodiments, at least part of the profile of each roofingcomponent has been moulded (i) by a CFT (as herein defined); and/or (ii)to accommodate a photovoltaic functionality; and/or (iii) to accommodateinterconnection functionalities of photovoltaic areas; and/or to defineat least in part said configuration; and/or (iv) to be very much greaterin dimension across the building surface to be covered than thedimension it will cover down said building surface; or (v) to be verymuch greater in dimension down the building surface to be covered thanthe dimension it will cover across said building surface.

In some embodiments, the dimension of the module in the direction thatextends across the building surface is at least 3 times, or at least 4times, or at least 5 times, or at least 10 times, or at least 15 times,or at least 20 times that of the dimension of the module that extendsdown the building surface. In some embodiments, the dimension of themodule in the direction that extends down the building surface is atleast 3 times, or at least 4 times, or at least 5 times, or at least 10times, or at least 15 times, or at least 20 times that of the dimensionof the module that extends across the building surface.

In a further aspect, the invention provides a roofing, cladding orsiding module or equivalent (“module”) comprising or including amoulding of a first material and a second material; wherein the firstmaterial defines a first region or first regions (“first region(s)”) anda second or second regions (“second region(s)”), whether profiled ornot; and wherein the second material defines an overlay or underlay ofat least part of one of said first and second regions; and wherein aplurality of said modules lapping their neighbour down or across abuilding surface with a notional or actual planar surface to be overcladby such a series of modules to form a weathertight seal over saidbuilding surface.

In a further aspect, the invention provides a roofing, cladding orsiding assembly comprising or including a structure to provide a supportsurface, and a plurality of modules to cover the underlying supportsurface, the modules relating to any neighbour(s) in an overlappingarrangement down the fall or pitch of the underlying surface, thereby todefine the exterior fall or pitch of the roofing, cladding or sidingassembly; wherein at least some of the modules include photovoltaic(“PV”) devices exposed to sunlight able to generate an electricaloutput; and wherein the plurality of modules define a pathway above thesupport surface for an air flow, induced or otherwise, to be heated byheat exchange from at least some of the modules as a consequence ofheating of the modules by received sunlight or heating of the modules asa consequence of the effect of received sunlight on the PV devices, orboth.

In a further aspect, the invention provides the use of a roofing,cladding or siding assembly as herein described to either orsimultaneously: (a) to generate electrical output from said PV devices;and/or (b) heat an induced or other air flow by heat exchange from atleast some of the modules as a consequence of heating of the modules byreceived sunlight or heating of the modules as a consequence of theeffect of received sunlight on the PV devices, or both.

In a further aspect the invention is a method of manufacture of aroofing, cladding or siding component, or substrate therefor, whichcomprises or includes the steps of: providing to at least one of theforming surfaces of a continuous or discontinuous forming machine a feedof material able to assume and retain a form after being moulded betweenthat first mentioned forming surface and a second forming surface, andallowing that formation to take place as such surfaces are advanced inthe same direction; wherein the output is of a form having a profiledregion to step out part of that region from an underlying actual ornotional planar surface, yet providing another region to, at least inpart, overlap said profiled region of a like form.

In a further aspect, the invention provides a method of manufacture of aroofing, cladding or siding component, or substrate therefor, whichcomprises or includes the steps of: providing material in liquid orviscous form to mould in a moulding position; allowing said material tobe moulded as a segment in said moulding position; advancing saidmoulded segment to a position subsequent to, yet partially overlappingsaid moulding position; providing further material in liquid or viscousform to the moulding position; allowing said material to be moulded as afurther segment in the moulding position along with, or so as to adhereto, the overlapping section of the previously moulded segment; whereinthe output is of a form having a profiled region to step out part ofthat region from an underlying actual or notional planar surface, yetproviding another region to, at least in part, overlap said profiledregion of a like form.

In a further aspect, the invention provides a method of manufacture of aroofing, cladding or siding component, or substrate therefor, whichcomprises or includes the steps of: (1) extruding or otherwise providinga feed of a first material to a supporting surface of a continuousforming machine, the feed having a width WI and thickness TI; (2)extruding or otherwise providing a feed of a second material to the topsurface of the feed of first material, the feed having a width WII andthickness TII; (3) allowing the two materials to be formed; and whereinthe output is of a form having a first profiled region to step out partof that region from an underlying actual or notional planar surface, yetproviding a second region to, at least in part, overlap said profiledregion of a like form; and wherein said second region is covered by bothmaterials, and said profiled region is covered, at least in part, byonly one of the materials. In one embodiment, the axis of advancement ofthe materials in the continuous forming machine is commensurate with thelongitudinal axis of a roofing shingle that is to lie with saidlongitudinal axis across the fall of a roof to be clad thereby.

In a further aspect, the invention provides a roofing, cladding orsiding component, or substrate of a roofing, cladding or sidingcomponent including product having a first region and a second region,the component to be used as a covering across the fall of a buildingstructure and to overlap at least in part with its first region, and tounderlap at least in part with its second region, the first and secondregions of a like component or substrate; wherein the component has beenformed by a feed of materials into a continuous forming machine toprofile at least one or either, or both, of the first and second regionsor at least parts thereof; and wherein the advance direction of thecontinuous forming machine defines the elongate axis of the componentthat is to lie across the fall of the building surface.

In another aspect, the invention provides a roofing, cladding or sidingmodule adapted to be fixed with its elongate axis across the fall of thebuilding surface to be clad; the module having a first longitudinalregion to underlie, in use, a like module or flashing, and a secondlongitudinal region, in use, to overlie a like module or to simply beexposed; wherein the first and second regions share in common a firstmaterial; and wherein the first and second regions share in common asecond material, yet the second region has its upper surface defined bya second material while only part of the first region (i.e. that part ofthe first region proximate to the second region) has its upper surfacedefined by said second material; and wherein there has been such sharingof the first and second materials since a continuous forming process;and wherein one, some or all of the following apply: (i) at least theunderside of the first region defines a profile of projections (egmesa-like or otherwise) to stand the remainder of the first region offfrom an actual support or notional support plane; (ii) such projectionsdefine a tortuous pathway above the actual or notional plane; (iii) thetopside of the first region, with depressions, provide a female versionof the male underside; (iv) the second material is weather resistant;(v) the first material has been foamed; (vi) the first material includesparticulate thermally conductive inclusion; (vii) the second materialcan self seal to a penetrative fastener; (viii) the first material is apolymeric material, the second material is a polymeric material, atleast the upper surface of the second region has been profiled; (ix) theupper surface of the second region has been profiled to simulateconventional roofing products (e.g. tiles, slate, shingles shakes or thelike); (x) the upper surface of the second region channels, pockets orthe like to accommodate or accommodating the buses and/or cells of aphotovoltaic array; (xi) the first and second materials have beencoextruded or serially extruded into a continuous forming machine; and(xii) the extrusion has been into an advancing continuous formingmachine where the elongate axis is aligned to the advancement.

In a further aspect, the invention provides a method of recoveringthermal energy from a building surface, said method comprising the stepsof covering the surface with a plurality of lapping modules such thatsaid modules are stood off from said surface to allow an air passage,inducing an airflow to pass through said air passage and collecting thethermal energy from the airflow subsequent to its passing through theair passage, wherein said modules are of a form having a first profiledregion to step out part of that region from an underlying actual ornotional planar surface, yet providing a second region to, at least inpart, overlap said profiled region of a like form; and wherein saidprofiled region includes a plurality of projections, such projections todefine a tortuous pathway above the actual or notional plane.

In a further aspect, the invention provides a roofing shingle, tile orequivalent module (“shingle”) substantially as herein described, with orwithout reference to the accompanying drawings.

In a further aspect, the invention provides a roof assemblysubstantially as herein described, with or without reference to theaccompanying drawings.

In a further aspect, the invention provides a building integrated solarenergy recovery system substantially as herein described, with orwithout reference to the accompanying drawings.

In a further aspect, the invention provides a roof clad by roofingcomponents of any aspect of the present invention.

In a further aspect, the invention provides a building surface clad bycladding or siding components of any aspect of the present invention.

The foregoing summary is illustrative only and is not intended to be inany way limiting. In addition to the illustrative aspects, embodiments,and features described above, further aspects, embodiments, and featureswill become apparent by reference to the following drawings and thedetailed description.

This invention may also be said broadly to consist in the parts,elements and features referred to or indicated in the specification ofthe application, individually or collectively, and any or allcombinations of any two or more said parts, elements or features, andwhere specific integers are mentioned herein which have knownequivalents in the art to which this invention relates, such knownequivalents are deemed to be incorporated herein as if individually setforth.

The invention consists in the foregoing and also envisages constructionsof which the following gives examples only.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an illustrative embodiment of a continuously formedroofing, cladding or siding module in its basic form.

FIG. 2 shows an illustrative embodiment of a continuously formedroofing, cladding or siding module fixed in an overlapping arrangementupon a building surface.

FIG. 3 shows the underlapping, exposed and fixing regions of anillustrative embodiment of the roofing module.

FIG. 4 shows an embodiment of the module having been formed to have asinusoidal profile to simulate concrete tiling.

FIG. 5 shows an embodiment of the module having been formed to have ajagged profile to simulate weatherboarding.

FIG. 6 shows an embodiment of the module having been formed to haverelief contours on its upper surface to simulate asphalt shingle.

FIG. 7 shows a series of modules fixed in a lapping arrangement withoffset vertical alignment for added visual appeal.

FIGS. 8A-8C show the detail of the fixing region of one embodiment ofthe module and the locators through which fasteners can be driven tosecure the module to the building surface.

FIG. 9 shows a nail type fastener sitting within a locator recess sealedoff by an overlapping module.

FIG. 10 shows an illustrative embodiment of the roofing module which hasbeen moulded to have a precamber.

FIG. 11A shows an embodiment of the module which includes adhesivestrips for securing the modules to create a weathertight seal. FIG. 11Bshows an exploded view of the module of FIG. 11A.

FIG. 12 shows an embodiment of the module where a first adhesive stripis affixed along the lower edge of the module on the back side of themoulded material layer, while a second is affixed to the top side justbelow the line of the fixing region.

FIG. 13A shows an alternative embodiment wherein the adhesive strips arepositioned so that both strips are on the front of the module; one atthe rear edge and one just below the line of the fixing region. FIG. 13Bshows an embodiment where a strip of material on the upper surface ofthe underlapping region serves as a weather-tight barrier.

FIG. 14 shows diagrammatically a continuous forming apparatuscontemplated as providing for the continuous forming of various modulesdescribed herein.

FIG. 15 shows a module wherein a second layer of material has beenformed overtop of, but not entirely covering, a first layer of material.

FIG. 16 shows an illustrative embodiment of a module wherein athermoplastic polyurethane layer has been formed along with, and on topof, a foamed polycarbonate layer, to give product characteristicsdesirable for a roofing shingle.

FIG. 17 is an exploded view of a roofing assembly to be used in thecollection of thermal and/or solar energy.

FIG. 18A is a side on view of the module assembly of FIG. 17. FIGS.18B-18C shows a cross-section of the module and air filter at the edgeof a building surface.

FIG. 19 is a diagram showing how heat recovered from the roofing systemcan be collected and used.

FIG. 20 shows a cross section of a profiled feature moulded as part ofthe underlapping region of a module.

FIG. 21A shows the underside of a module with projection featuresincluded to encourage turbulent flow of the underpassing air stream.FIG. 21B shows a module surface (as seen in FIG. 21A) with a series offine ribs integral to the moulding so as to increase the module'scontact surface with the air stream and assist heat transfer. FIG. 21Cis a close up view showing the profile of the ribs of FIG. 21B.

FIG. 22 shows two modules positioned in a lapping arrangement and havingcomplementary surface textures on their respective contact surfaces.

FIG. 23 shows an overlapping series of one embodiment of the moduledesigned to carry a solar array for photovoltaic power generation.

FIG. 24 is a detailed view of the module of FIG. 23.

FIG. 25 shows a method of endwise joining two modules with an overlaidsolar panel secured across the joining region.

FIG. 26A shows the detail of the relief features on the surface of thebuilding integrated photovoltaic embodiment of the module which aredesigned to locate a series of electrically connected photovoltaiccells. FIG. 26B shows the detail of the channels configured to receivecables or wires of the photovoltaic array cavities configured to receivejunction boxes. This figure also shows surface marking to indicate thelocation position of the underlying electrical fittings and connections.

FIG. 27 shows diagrammatically a continuous forming apparatuscontemplated as providing for the continuous forming of modules andlending itself to the online introduction downstream of a photovoltaicfunctionality system.

FIG. 28 shows a building on which various embodiments of the currentinvention have been installed.

FIG. 29A shows the detail of a concertina feature designed toaccommodate thermal expansion and contraction of the module. FIG. 29Bshows the detail of the concertina feature placed between two fixingpoints.

FIG. 30 shows a “dummy” module positioned in a lapping arrangement witha cutout for a pipe emerging from the building surface. BIPV modules areshown on either side of the “dummy module”.

DETAILED DESCRIPTION

It is to be appreciated that certain aspects, modes, embodiments,variations and features of the invention are described below in variouslevels of detail in order to provide a substantial understanding of thepresent technology.

The present technology is described herein using several definitions, asset forth throughout the specification. Unless otherwise stated, thesingular forms “a,” “an,” and “the” include the plural reference. Forexample, a reference to “a device” includes a plurality of devices.

As used herein the term “and/or” means “and” or “or”, or both.

As used herein “(s)” following a noun means the plural and/or singularforms of the noun.

Relative terms, such as “lower” or “bottom”, “upper” or “top,” and“front” or “back” may be used herein to describe one element'srelationship to another element as illustrated in the Figures. It willbe understood that relative terms are intended to encompass differentorientations of the device in addition to the orientation depicted inthe Figures. For example, if the device in one of the figures is turnedover, elements described as being on the “lower” side of other elementswould then be oriented on “upper” sides of the other elements. Theexemplary term “lower”, therefore, encompasses both an orientation of“lower” and “upper,” depending of the particular orientation of thefigure. Similarly, if the device in one of the figures is turned over,elements described as “below” or “beneath” other elements would then beoriented “above” the other elements. The exemplary terms “below” or“beneath” can, therefore, encompass both an orientation of above andbelow.

The term “comprising” as used in this specification means “consisting atleast in part of”. When interpreting statements in this specificationwhich include that term, the features, prefaced by that term in eachstatement, all need to be present but other features can also bepresent. Related terms such as “comprise” and “comprised” are to beinterpreted in the same manner.

As used herein, the term “formed surface” refers to a moulded segment ofa polymeric material corresponding to an individual die or mold of acontinuous forming machine.

As used herein, the term “building surface” refers to a wall surface ora top surface, etc. of a building, e.g. an exterior wall, a roof, aceiling, etc., unless otherwise specified. In the context of a roof, thebuilding surface typically comprises a waterproof roofing membraneattached to the roof deck adjacent an eave of the roof for preventingwater damage to the roof deck and an interior of a building fromwind-blown rain or water buildup on the roof. The roof deck is typicallymade of an underlying material, such as plywood. The waterproof membranemay be any of a number of waterproof roofing membranes known in the artsuch as but not limited to bituminous waterproof membranes, modifiedbituminous roofing membranes, self-adhering roofing membranes, or singleply waterproofing roofing membranes (e.g. EPDM waterproof roofingmembranes, PVC waterproof roofing membranes, TPO waterproof roofingmembranes). One exemplary membrane sheet is Deck-Armor™ Roof Protection,manufactured by GAF Corp., Wayne, N.J.

As used herein, the term “roofing” means the provision of a protectivecovering on the roof surface of a building. Without limitation, such aprotective covering might take the form of shingles, tiles, panels,shakes, planks, boards, modules, mouldings or sheets.

As used herein, the terms “cladding” and/or “siding” mean the provisionof a protective covering on a side or other surface of a building.Without limitation, such a protective covering might take the form ofshingles, tiles, panels, shakes, planks, boards, modules, mouldings orsheets.

As used herein, the terms “profiled” and/or “contoured” mean having aregion, or regions which extend above or below a notional planar surfacelying along the longitudinal axis of the product. This includesprofiling or contouring of only one upper or lower surface, and/orprofiling or contouring of an entire thickness of material such that theupper and lower surfaces have the same relative degree of extensionabove or below the notional planar surface.

As used herein, the term “thermally conductive particles” or “thermallyconductive inclusions” refers to particles or inclusions of anyconductive material. These include, but are not limited to, particles ofthe following materials: metals, metal hybrids, carbon, silica, glass,conductive polymers, salts, carbon nanotubes and compounds of thesesubstances. In addition to assisting in heat transfer, the thermallyconductive particles or inclusions may also act as a reinforcingmaterial.

As used herein, the term “polymer” (and associated terms such as“polymeric”) includes polymers, polymer blends, and polymers with orwithout additive inclusions.

The present technology relates to a cladding or roofing product. In someembodiments, the product comprises modules having g a plurality offormed surfaces moulded from one or more polymeric materials (which maybe in layers), wherein each of the formed surfaces comprises threedimensional surface features. The present technology also relates to aproduct having good thermal conductivity and a capacity for photovoltaic(“PV”) and/or solar thermal energy generation, and relatedsubassemblies, assemblies, uses and methods. The present technology hasseveral advantages. For example, the roofing, cladding or siding productmay reduce the amount of heat energy transferred to the interior of thebuilding upon which it is mounted; and/or to provide a system whichincorporates a roofing, cladding or siding product to that effect;and/or to provide a method by which mass production of such a productcould be achieved; or at least provides the public with a useful choice.

In other embodiments, the present invention provides a BuildingIntegrated Photovoltaic (“BIPV”) and/or solar thermal roofing, claddingor siding product which is reasonably light weight, easy to install,durable and resistant to environmental wear; or at least provides thepublic with a useful choice.

In other embodiments, the present invention provides a BIPV and/or solarthermal roofing, cladding or siding product that does not require afastener (nail, screw, bolt, etc.) to penetrate the exposed surfaces ofthe roof, thereby making the product less likely to leak compared toconvention BIPV products; or at least provides the public with a usefulchoice.

In other embodiments, the present invention provides a BIPV and/or solarthermal roofing, cladding or siding product capable of large surfacearea coverage, that can be mass produced in high volumes and withreasonable speed of production; and/or to provide a method by which suchmass production of such a product could be achieved; or at leastprovides the public with a useful choice.

In other embodiments, the present invention provides a BIPV and/or solarthermal roofing, cladding or siding product which will allow heat energyto be transferred away from the photovoltaic cell to maximise itsoperational efficiency; and/or to provide a system which incorporates aBIPV roofing, cladding or siding product to that effect; and/or toprovide a method by which mass production of such a product could beachieved; or at least provides the public with a useful choice.

In other embodiments, the present invention provides an airway path toallow space for wires and other electrical components to run between theroof and the building structure with such wires and electricalcomponents located above a waterproof membrane on the building substratesurface therefore ensuring that the waterproof membrane is notpenetrated (as seen in FIG. 23).

In yet other embodiments, the present invention provides a buildingintegrated system which allows solar, ambient and photovoltaicallygenerated heat to be transferred away from a building surface and usedelsewhere; and/or the components of such a system; and/or a method ofmanufacturing such components; or at least provides the public with auseful choice.

Various embodiments of the present invention relate to a roofing,cladding or siding product to be secured to a building in a lappingarrangement. In one embodiment the product is formed as a module to belaid horizontally across a surface and lapped vertically down thatsurface, however, it is also possible to manufacture the product so asto allow it to be laid in vertical columns which would then lap acrossthe surface. In particular, three illustrative embodiments of theproduct are described below. The first is a module which can be used toform a weatherproof covering over top of a building surface; the secondis a module which can, in additional to forming a weatherproof covering,be used as part of a thermal energy recovery system; and the third is amodule which can, in addition to forming a weatherproof covering, andoptionally in addition to being useful as part of a thermal energyrecovery system, bears an array of solar cells to generate electricalenergy.

In the following description the general features of the product andtheir functional advantages are described. It should be appreciated thatall of the various features may or may not be present depending on whichembodiment of the module is required. Furthermore, there may be variouscombinations of the features and combinations of the embodiments, whichalthough not specifically referred to, are intended to be covered bythis specification.

In one aspect, the present invention provides a roofing, cladding orsiding product which is reasonably light weight, easy to install,durable and resistant to environmental wear. In some embodiments, theroofing, cladding or siding product is capable of large surface areacoverage, can be mass produced in high volumes and with reasonable speedof production; and/or provides a method by which such mass production ofsuch a product can be achieved.

In one embodiment, the roofing, cladding or siding product is a modulecomprising a plurality of formed surfaces moulded from one or morepolymeric materials (which may be in layers), wherein each of the formedsurfaces comprises three dimensional surface features, and wherein theformed surfaces are joined without weld lines or injection mouldingpoints. Each formed surface refers to a moulded segment along the lengthof the module that corresponds to an individual dye or mold of acontinuous forming machine. See PCT/NZ2006/000300 (published asWO2007/058548). Use of the term “joined” in this context is not intendedto require that each of the formed surfaces were ever separated, i.e.,the formed surfaces may be integrally formed together in situ during themanufacturing process. In another embodiment, the module design featurescan be achieved by thermoforming, pressing, or other method of forming,either continuously or discontinuously wood, metal, concrete, resins,glass, clay, composites or the like.

In particular, the product can be manufactured in long strips (as seenin FIG. 1) by a continuous process which incorporates a continuousforming step, and therefore can be made in varying lengths as requireddepending on the required coverage area. Production is such that asingle moulded module, capable of extending across the entire width orsection of the roof or building to be protected, can be manufactured.For example, the modules may be very much greater in dimension acrossthe building surface to be covered than the dimension it will cover downthe building surface. In one embodiment, the dimension of the module inthe direction that extends across the building surface is at least 3times, or at least 4 times, or at least 5 times, or at least 10 times,or at least 15 times, or at least 20 times that of the dimension of themodule that extends down the building surface. Alternatively, themodules may be very much greater in dimension down the building surfaceto be covered than the dimension it will cover across the buildingsurface. In one embodiment, the dimension of the module in the directionthat extends down the building surface is at least 3 times, or at least4 times, or at least 5 times, or at least 10 times, or at least 15times, or at least 20 times that of the dimension of the module thatextends across the building surface.

In some embodiments, the modules are about 0.2-1 in length, 1-20 metersin length, about 3-10 meters in length, or about 4-8 meters in length,or 2-4 meters in length. Modules of 4-5 meters in length, and modules of8 meters in length are suitable manufacturing sizes, but themanufacturing process allows custom lengths to be accommodated just aseasily. A plurality of such modules can then be arranged in lapping rowsdown the surface of the structure, for example, as shown by the lappingroof shingles seen in FIG. 2.

The features of an illustrative embodiment of the basic roofing productare as shown in FIG. 3. There is an underlapping region 301, and anexposed region 302 (i.e. to be exposed when a series of modules arepositioned in a lapping arrangement). There may also be a fixing region303 where the module 300 is to be attached to the building surface, andthis may or may not be within the underlapping region 301, but issuitably or optionally within the underlapping region 301. The regionsmay exist in various proportions comparative to each other, and theremay be profiling or contouring 304 of any or all regions in a continuousor discontinuous pattern along the length of the module 300. In oneembodiment, the width of the underlapping region 301 approximatelyequals the width of the overlapping region 302. In other embodiments,the width of the underlapping region 301 is about 95%, about 90%, about80%, about 75%, about 60%, about 50%, about 40%, about 30%, about 25%,about 15%, or about 10% of the width of the overlapping region 302. Insome embodiments, the overlapping region 302 is from about 5 cm to about60 cm wide and the underlapping region 301 is from about 5 cm to about60 cm wide.

Variations in the profiling or contouring can be used to createdifferent stylistic or ornamental effects. For example, the module maybe moulded with a sinusoidal profile, as shown in FIG. 4, to simulateconcrete tiling; an angular profile, as shown in FIG. 5, to simulateweatherboarding; with relief features on its upper surface, as shown inFIG. 6, to simulate asphalt shingles; or with a variable upper surfacecontour to simulate slate tiling or wooden shakes. The continuousforming process allows a variety of different 3D surfaces to be producedwith the same equipment simply by swapping out the die faces on theforming machine as required.

The colour and visual properties of material feeds can be changed fairlyeasily also just by inputting different materials and additives(particularly colouring additives) at the feeding stage. This means thatit is possible to mass manufacture consecutive runs of different typesof product (e.g. a product simulating concrete tiles, a productsimulating slate tiles and a product simulating asphalt shingles)without significantly altering the equipment on the manufacturing line.

The modules may be installed in various vertical alignments as desiredand/or as permitted by the surface contouring. The offset verticalalignment shown in FIG. 7 gives the effect of traditional “tiled”roofing, while other alignments will also produce interesting visualand/or stylistic effects.

FIG. 8A shows a series of locator recesses 801 within the fixing region802 of a moulded module 800 for locating nail or screw type fasteners.There are bosses 803 (i.e. thickened sections of material) at the bottomof each recess to provide a strong area for the fastener shank to passthrough, and these also create a flat surface 804 to butt with thebuilding surface underneath the module. The sides of the recess 805slope outward so that a hammer or pneumatic nail or staple gun can beused to drive the fastener home without damaging the surrounding modulematerial.

FIG. 8B shows there may be “starter” holes or locators 801 within thefixing region 802 for locating the fasteners 806 (e.g., nails, staples,or screws) which attach the module to the building surface. Theselocators 801 can be moulded features or extra surface markings. Thepurpose of such locators 801 is to simplify installation by showing howmany fasteners 806 are required and how far apart they ought be spaced.Furthermore, as shown in FIG. 8C, the locators 801 may include recessesthat are adapted to fit conventional nail or screw gun heads 807. Thisprovides easy alignment and accurate location of the fastener for theinstaller. There may be a layer of reinforcement material covering thefixing region of the module to prevent the module material from tearingwhere it is penetrated by the fasteners, in which case the locators canserve to ensure that the fasteners are positioned within the reinforcedzone.

Once the module is fixed to the roof the head of the fastener should beflush with or sit below the top of the locator opening. As shown in FIG.9, this allows the overlapping region of a subsequently affixed moduleto sit flat over top of the first module.

The module may be formed with a convex precamber (as shown in FIG. 10)to apply a pre-load pressure to encourage the edges and bottom surfaceof the overlapping panel to contact firmly onto the underlapping panelwhen installed on a building. This also provides high thermalconductivity between the underlapping panel and the overlapping panel.Additionally, adhesive strips 111 (shown in FIG. 11A) running along thelength of each module can be used to connect one module to the surfaceof the next, creating a waterproof seal and stopping grit andparticulates from working their way under the roofing or cladding layer.There is also an advantage to securing those regions of the module whichare farthest from the fixing region so that the exposed portions of themodule cannot flap up in the wind and cause damage through fracture orbending stresses. This may be done with adhesive strips or by othermeans. If adhesive strips are used, it may be beneficial to have themcovered by release strips 113 for transport and storage (as showing inFIG. 11B). The release strips would be removed during installation.

The placement of the adhesive strip(s) on the module can vary. As shownin FIG. 12, in one embodiment, a first adhesive strip 121 is affixedalong the lower edge of the module on the back side of the mouldedmaterial layer, while a second 122 is affixed to the top side just belowthe line of the fixing region. Thus a series of modules can be arrangedas shown in FIG. 12, where the strip on the back side adheres to thestrip on the front side.

Alternatively, as shown in FIG. 13A, the adhesive strips can bepositioned so that both strips are on the front of the module; one atthe rear edge 131 and one just below the line of the fixing region 132.In this case the adhesive will secure two points of the module and willadhere directly to the substrate layer of the overlapping module. Afurther alternative or addition is to apply an adhesive paste to theregion 112 during installation.

As shown in FIG. 13B, the module may be pre-formed with a strip ofmaterial 133 on the upper surface of the underlapping region that servesas a weather-tight barrier when placed into contact with an adjacentmodule. This flexible strip of material 133 prevents the backflow ofwater or air in between the overlapping modules. A further alternativeor addition is to place a similar strip of polymeric material on thelower surface of the exposed region, to prevent water from penetratingbetween the two overlapping modules.

In one embodiment, a sequence of steps in the manufacture of the roofingand/or cladding product is to firstly prepare the module material forforming (which may involve bringing the material to a molten,semi-molten or pliable state), secondly, feeding the material to apressure forming zone, and thirdly, forming and setting the material asit advances through the pressure forming zone. While there are variousmethods of mixing and presenting the materials prior to forming, asuitable method is to deposit an extruded feed layer of a first material141 onto an advancing support surface of a continuous forming machine,and to subsequently introduce a further extruded feed layer of anothermaterial 142 overtop of this, as shown in FIG. 14. The first materialand the second material or additional may be the same or different, andmay be of the same or different form. Both materials then proceed as alayered feed 143 to the pressure forming zone 144, and are moulded intoa single module panel 145. The product can be manufactured so that thereare different features on the top of the moulded panel to those on thebottom by using different dies in the upper and lower rotating tracks146 of the CFT machine. The modules can also be manufactured using asingle material only.

Upon arrival at the pressure forming zone it may be that the secondmaterial feed entirely covers the first, however the feeds may bearranged so that only a portion of the first feed 151 is covered by thesecond 152 (as in FIG. 15). There may only be a thin strip of the secondmaterial or additional material on top of the first or second feed, andthe positioning of the strip across the width of the first feed canvary. These variations can be achieved during manufacture by changingthe positioning of the various extruders relative to each other and byaltering the width of the feeds.

In some embodiments, the first material layer has a width WI and athickness TI and the second material layer has a width W2 and athickness T2. In one embodiment, WI is wider than WII. In oneembodiment, WI and WII are of equal widths. In one embodiment, WII iswider than WI. In one embodiment, TI is thicker than TII. In oneembodiment, TI and TII are of equal thickness. In one embodiment, TII isthicker than TI. In one embodiment, WI and WII are within the range of 5centimeters to 3 meters. In one embodiment, TI and TII are within therange of 0.1 to 100 millimeters.

Additional material layers (whether extruded, roll fed, or otherwisepresented) can also be added prior to or after the forming process. Thisallows for the continuous forming of a multi-layered product, eachmaterial layer having a particular set of properties which areadvantageous to the product. In particular, it may be desirable to addone or more reinforcing layers to the product. Such layers may comprisea metal, cloth or fibreglass mesh, jute or other fabric, glass fibre,carbon fibre, aluminium sheet or a reinforcing polymer. These can belaid beneath, on top of, or in between the other material layers priorto the forming step, and may or may not undergo deformation during theforming step. The thickness of the module panel 153 produced will bedetermined in part by the materials selected and the number of layersfed in. In one embodiment the thickness of the panels may be within therange of about 0.5-55 mm.

The various layers of material may chemically bond together prior to orduring the forming step, however their ability to do so will dependentirely on the materials selected. Where the materials selected are notprone to chemical bonding, it may be necessary to assist adhesion with aplasma or adhesive layer; or to feed in a supplementary material with achemical affinity for both of the material layers. This can be appliedin-line as an interposing layer or deposit atop the first substratematerial feed prior to the introduction of the second. The variouslayers of material may also mechanically bond together due to thesurface finishes or features between the layers.

A similar product can be achieved by the segmental injection moulding ofthe roofing and/or cladding modules, however such a process has a muchslower output capacity. Large areas of product need to be produced forbuilding applications and it is desirable to be able to produce theselarge surface area products in high production volumes to make theprocess economical. Moreover, such a process would result in a productcontaining weld lines and injection moulding points. Weld lines areformed when two or more molten polymer flows meet during the injectionmolding process. This can occur when a polymer flow splits to go aroundan interruption (e.g., a post that forms a hole) and then rejoins, orwhen polymer melt fronts meet, from multiple injection points. This canalso occur when molten polymer meets a non molten polymer. Consequently,a visible weld line is observed and the adhesion/bond in this weld lineat the interface is weaker than the balance of the polymer within theproduct. Injection moulding points are the area of a product where theheated material was fed into the mold cavity. It is also difficult tomake a product comprising more than one layer of material usinginjection moulding, and injection moulding can produce colourdifferences or variations that affect the aesthetics of the finalproduct. On the other hand, the continuous forming machine can produceapproximately 5-60 m of product per minute, which makes it a preferableto use this production method over other processes which could be usedto manufacture a 3D polymer product. The continuous forming machine alsoproduces a product that lacks weld lines or injection moulding points,and optionally contains multiple layers of material.

A number of materials are suitable for use in the production of aroofing and/or cladding product by a continuous forming process; howeverit is most cost effective to produce the moulded panel from a foamedmaterial (e.g. foamed polycarbonate). Not only does this reduce theamount of raw material required for production, but also results in alightweight product. This can be advantageous in the retrofitting ofroofing or cladding to an existing building. For example, where there isa building with an existing but degraded roof, re-roofing can occur byplacing the new lightweight shingle directly over top of the existingshingle (usually asphalt shingle).

The foamed polycarbonate (or alternative substrate material) may beaccompanied by one or more additional materials to enhance theproperties of the product. A suitable material is ThermoplasticPolyurethane (TPU), which can be fed into the moulding process alongwith the polycarbonate as shown in FIG. 14. Foamed polycarbonate andsimilar materials are favoured in roofing products because they havefire retardant properties, but the addition of a TPU layer improves theperformance of the product because the TPU has better durability,physical properties and resistance to environmental wear. In particular,TPU is puncture resistant, tear resistant, and UV resistant, and willretain the aesthetic appeal of the product for a longer period of timecompared to polycarbonate alone.

The panel at its point of exit from the forming step is shown in FIG.16. The TPU layer (or a layer of alternative material) 161 is moulded ontop of the polycarbonate (or other foamed material) layer 162 to formthe body of the shingle module. While it is desirable to use as muchfoamed material as possible to reduce materials, in some embodiments,the TPU layer may cover the region 163 which extends from the lower edgeof the shingle up to a line above the fastener fixing region. This is sothat the areas of the shingle exposed to the elements will have gooddurability, and all of the areas of the shingle penetrated by fastenerswill have good tear resistance. An advantage to using TPU in thisinstance is that the TPU, once punctured, will tend to contract aroundthe shank of the fastener to make a watertight seal.

Other materials which may be used include (but are not limited to)polycarbonate (PC), general purpose polystyrene (GPPS), polymethylmethacrylate (PMMA), polyethylene terephthalate (PET), polyestermethacrylate (PEM), polypropylene (PP), high impact polystyrene (HIPS),acrylonitrile butadiene styrene (ABS), polyester (PES), polyamides (PA),polyvinyl chloride (PVC), polyurethanes (PU), polyvinylidene chloride(PVDC), polyethylene (PE), polytetrafluoroethylene (PTFE),polyetheretherketone (PEEK) (polyetherketone), polyetherimide (PEI),Polyimide (PI), polylactic acid (PLA), high impact polystyrene,acrylonitrile butadiene styrene (ABS), acrylics, amorphous polymers,high density polyethylene (HDPE), polyethylene terephthalate (PET), lowdensity polyethylene (LDPE), linear low density polyethylene (LLDPE),medium density polyethylene (MDPE), cross linked polyethylene (PEX),Ethylene vinyl acetate (EVA), Ethylene vinyl alcohol (EVOH),thermoplastic elastomer (TPE), thermoplastic polyolefin (TPO),thermoplastic rubber (TPR), polypropylene (PP), Fluorinated ethylenepropylene (FEP), Polybutylene terephthalate (PBT), Polyoxymethylene(POM), Polyphenylene oxide (PPO), Polypropylene homopolymer (PP-H)Polypropylene copolymer (PP-C), silicon polymers, styrene-acrylonitrileresin (SAN) and thermoplastic rubber. The materials may be a blend ofany or all of these. The materials may also comprise additives toenhance properties such as resistance to fracture, impact, ultravioletlight, and thermal or tensile stresses. Materials which could also beconsidered in manufacture are various polystyrenes, nylons, acrylics,polyethylene, thermoplastic ethylene, polypropylene and phenolic, andcombinations of or containing these. No matter which materials arechosen, the materials must be compatible so that they do not delaminate.If the materials are not compatible, they may still be used; however, atie or bond layer must be introduced between them. Examples of tie orbond layers include, but are not limited to, ethylene vinyl acetate(EVA), thermoplastic polyolefin (TPO), thermoplastic elastomer (TPE),silicon adhesives, epoxy adhesives, and acrylic adhesives. One of skillin the art is capable of choosing materials in the appropriatecombinations to suit the purposes described herein.

In various embodiments, the roofing module is flame resistant, resistantto tearing (especially at puncture and attachment points), able to beeasily and cleanly cut with everyday tools to aid installation, able toendure environmental and UV exposure for over 20 years, able to endurecyclic freezing and thawing without failure, resistant to delaminationat temperatures of between −40 and 100 degrees Celsius, impact resistantto a reasonable extent, impenetrable by water even at fixing points, lowdensity, resistant to penetration and abrasion, colourfast, resistant tomicrobial attack, compatible with adhesives and made of materials whichare stable in high humidity and wet conditions and which retain theirpliability at high and low temperatures and which do not delaminate. Allof these factors come into play when choosing appropriate materials ormaterial combinations for the manufacture of the product. It is alsodesirable that the material(s) used are non-toxic, or that at least theupper layers of the product are (if a layered product is produced). Thisavoids the prospect of toxic contamination in the event that water is tobe collected from one or more building surfaces for subsequent use.

In some embodiments, the product may be produced from a recyclablematerial or several different recyclable materials. The combination ofmaterials chosen in the manufacture of the product is suitably one thatcan be recycled without first having to dismantle the product into itsconstituent materials.

It is also important to choose a material with a low co-efficient ofthermal expansion to avoid warping along the length of the product. Ifthe material undergoes too much movement once attached to the buildingsurface it may fail at or between the attachment points. Failure canalso be a problem if a layered product is produced with two or morematerials having vastly different thermal expansion co-efficients. Inone embodiment, as shown in FIGS. 29A-29B, thermal expansion andcontraction can be accommodated by moulding each module to have one ormore concertina-shaped features 291 that will expand or contract betweentwo fixing points 292.

In various embodiments, the roofing or cladding module may incorporateadditional properties or functionalities, including but not limited to:a photovoltaic functionality; and/or (iii) interconnectionfunctionalities of photovoltaic areas, as described in further detailbelow.

An alternative embodiment of the roofing and/or cladding product of thecurrent invention is one that has all of the previously describedfeatures, along with several additional features that make the productsuitable for use as part of a thermal energy recovery system. Thethermal energy can be obtained from a building surface that has beenexposed to sunlight for a period of time, although there are other lesssignificant sources that may contribute. The thermal energy can then beexhausted or transferred to a passing fluid flow (air being the mostpractical option) between the product and the building surface, andsubsequently used elsewhere in the system.

A notable feature of this embodiment is that the building underlay formsone boundary of the airway path. This embodiment is different from box,round or other geometric closed cross section shapes e.g. Corflute® roofor similar products, which are segmented into confined zones for airflowthat can become blocked. The overall cost of materials is also reducedcompared to box, round or other geometric closed cross section shapedroofing materials, which contain a backing material to define aself-contained pathway for airflow. By contrast, this embodiment regardsthe whole roof as one large surface of airflow, with the cavity forairflow bounded on one side by the modules and the roofing underlay onthe other side.

As an example of such a system, FIG. 17 shows a roof assembly involvinga series of overlapping shingle modules. FIG. 18A shows an illustrativeembodiment of two modules from side on. The roofing underlay, such as aplywood surface and/or a weatherproofing, insulating or highlyreflective membrane 171, and the layer of roofing shingle will beslightly set off from the membrane so that there is a gap 181 to allowthe passage of an air stream between the two layers. The gap can bemaintained by features of shape integral to the shingle module moulding182 or by additional spacer/standoff components. Thus, the roof assemblyforms a single layer on top of the building underlay but the formedfeatures 182 (i.e., the profiled “feet” on the underside of theunderlapping region) make the stand-off for the air to pass through.FIGS. 18B and 18C illustrates a tile at the edge of the building surfaceand shows that a filter 184 can be placed between the tile and thebuilding underlay to allow for the passage of air from the outside intothe set off. It is most efficient to force the air in the directionwhich it would naturally travel as it gets hotter, i.e. from the bottomof the building surface to the top; however alternative embodimentswhere the air is drawn across the surface may also be conceived. Thewarm air can then be drawn through inlet spigots 172 near the upper edgeof the surface into a central manifold duct 173. The warm air can beexhausted directly to the atmosphere or used elsewhere in the building.

FIG. 19 shows how the energy from the warmed air can be used elsewherein the building. A fan 191 can be used to create airflow to pull the airinto the manifold duct. The warmed air can then be expelled from the fanand used as the working fluid of a heat exchanger 192 which can beemployed as required, for example in water heating 193 or airconditioning 194. Alternatively the hot air can be directly used forheating applications. A flap valve (not shown) may be installed torelease hot air from the manifold duct in the event that the fan fails.In some embodiments, the airflow is reversible, such that warm air canbe directed from the heat exchanger to the roof in order to, forexample, melt snow or ice on the roof, purge residual moisture, or cleardust, dirt, or debris from the system. Different manifolds may also beincluded to direct warm air from one part of the roof to anotherdepending on the energy need. For example, air may be directed from asun-exposed portion of the roof to a shaded, snow-covered portion inorder to melt snow from that portion. Other variations would be readilyapparent to one of skill in the art.

In some embodiments, the speed of the fan is proportional to the thermalenergy received in a particular area of the roof. The fan speed can becontrolled in a variety of ways, including temperature sensors ortimers. In one embodiment, the fan speed is controlled by driving theelectric motor using one or more dedicated PV cells on the surface ofthe roof. Thus, the fan control will be directly related to how hotand/or intense the sun is on certain parts of the roof at differenttimes of the day. For example, a building surface may be divided intosections in which separate fans control airflow in each section, e.g. astandard house might have four sections and each would have its own fanwhich would increase in speed as the intensity of the sun increases onthat side of the roof and decrease in intensity as the sunlightintensity decreases. As such, the fans in the different sections will beincreasing and decreasing in speed depending on whether the particularsection is in full sun or is partially shaded.

In one embodiment, a thermal embodiment of the module can be moulded orprofiled with a raised patterning 211 in the underlapping region todefine a tortuous pathway above the actual or notional plane. Thiscauses turbulence in the flow of the forced fluid and thereforeincreases the convective heat transfer from the module to the flowingfluid. As described in detail in the next section, when PVfunctionalities are included on the module, the feet also provide apassageway for the wiring for electrical connection, e.g. to the PVcells, and allow for the incorporation of electronics into the shingle.The feet may be designed to also provide strength so that if a personwalks on the shingle it will not crush or fold under. The feet may alsobe designed to provide an even airflow across the entire airway space.The feet may also be designed to provide a minimal pressure drop betweenthe air intake and the air outlet. The feet may also be designed toprovide for the location and securing of cables and Tee fittings. Thefeet may also be designed to provide a pathway for the cables and Teefittings that has minimal obstruction. The pathway for the cables may bevertical, horizontal or diagonal.

There are many different patterns which will achieve this, including thealternating pattern of mesa-like projections shown in FIG. 21. Again theproportion of the shingle which is patterned may vary in comparison tothe size of the underlapping region. The projections on the underside ofthe module need not be the same across the entire width. In oneembodiment, the projections decrease in height as one moves across thewidth of the tile such that there is a taper between the buildingsurface and the underlapping region of the module. Therefore, when anoverlapping module is placed on top, it is kept parallel to the buildingsurface. For example, the projections may reduce in size from about 21mm to about 16 mm as one moves towards the back of the tile to make iteasier to fit the overlapping tile and keep the overlapping tileparallel to the building surface. The shape and layout of theprojections may also vary.

In another embodiment, the patterning is in the form of a corrugationbetween the module and the building surface. For example, the module canbe moulded into alternating parallel grooves and ridges.

FIG. 20 shows how the profiles may have chamfered sides 201 or otherfeatures of shape to prevent water from gravity pooling in thedepressions when the underlying surface on which the product isinstalled is an angled surface (for example a roof). A series of fineribs 212 moulded on the underside of the module, or roughened surfacetexture, could alternatively or additionally be used to createturbulence in the air flow. This will also create more surface area forconductive heat transfer from the module. In some embodiments, thegeometry of the ribs or texturing can be chosen to assist in heattransfer. For example, if the texture is, in profile, a series oftriangular peaks 213, this will allow more efficient heat transfer tothe passing air flow than if the texture is, in profile, a series ofsquare toothed projections.

As a further option, the surfaces which come into contact when lappingcould have complementary texturing on them to assist theirinterengagement; for example, as shown in FIG. 22. A thermallyconductive paste or adhesive may additionally or alternatively beapplied between the contact surfaces to enhance this, or the adhesivestrip feature may be thermally conductive or have a thermally conductivecomponent. In one embodiment, the upper and lower surfaces of the underand overlapping modules respectively have a serrated profile 221 capableof interlocking when the modules are in position. The serrations can beshaped so that they “wedge” into each other and exert some degree ofcompressive force against one another. The surface textures mightotherwise be splines, knurls, teeth or undulations of another type. Thetexturing brings the surfaces into better contact so that there is moresurface area to facilitate heat transfer between the lapping modules,and could also be used to aid in locating the modules when they areinstalled on a building surface.

Although foamed materials reduce the cost and weight of the product, theair inside the foam acts as a heat insulator. This can be advantageousif you want to stop heat from the sun being transferred into the ceilingcavity of the building, but it is not ideal for heat transfer in anenergy recovery system. Therefore the thermal embodiment of the roofingand/or cladding product may be adapted to increase its heat transfercapacity. In order to achieve a foamed material with high heatconductivity, thermally conductive particles (e.g. aluminium flakes) canbe introduced into a polymer prior to the forming process. The particleshelp to create a heat pathway through the material and increase theoverall thermal conductivity significantly. The particles may alsoprovide structural reinforcement to the material. For example, where amodule moulded from polycarbonate may have a thermal conductivity of 21W/mK, the same module moulded from a loaded polycarbonate blend having30% aluminium will have a thermal conductivity of 25 W/mK. A modulemoulded from 3% foamed polycarbonate may have an even lower thermalconductivity of 18 W/mK, but this can be improved to 24 W/mK with theaddition of 30% aluminium. The module material can be loaded with thethermally conductive substance prior to the manufacture of the module.

In order to prevent the final product from being too brittle, acompatiblising polymer, such as an ionomer, can be blended with themetal particles changing them from a reactive contaminant to areinforcement agent with elevated levels of thermal conductivity. It isdesirable to have some degree of elasticity to the formed material foruse in building product applications.

Another embodiment of the roofing and/or cladding product of the currentinvention is that which is adapted for use in a system to generateelectrical energy from solar power. Such products are generally referredto as building integrated photovoltaic products (“BIPV”). As shown inFIG. 23, a series or array of photovoltaic cells may be carried on theexposed region of the module so that they capture photons when installedon a building surface.

FIG. 24 shows a more detailed view of an energy generating module, whichmay comprise one or more moulded material layers 241, a solar arraylayer of connected photovoltaic cells 242, and an optional transparentsurface laminate layer 243. The energy generating module may alsocomprise bonding/encapsulation/tie layers to the front and/or back ofthe PV layer and may also contain layers to stop the corrosion of the PVlayer e.g. polyethylene, EFTE, etc. On the solar array layer, typicallyor optionally each of the photovoltaic cells in the row are connectedvia two bus strips which extend the entire length of the module; onerunning across the upper edges of the cells 244 and one running acrossthe lower edges 245. The advantage of this is that the bus stripscontact all of the cells so that only a single electrical junction foreach module need be connected to a main power take-off on installation.A further option is to have the bus strip material integrally mouldedinto the substrate panel during the forming process.

FIG. 11B shows an exploded view of all of the layers of an illustrativeBIPV product. The transparent laminate 243 is over a solar array layerof connected photovoltaic cells 242, which is over a moulded materiallayer 241. The release sheet 113 of an adhesive strip 121 are alsoshown. Optional adhesive, tie, or bonding layers (not shown) may beadded to the surface of any of the layers.

Where it is necessary to join two modules across the width of a surface(i.e. the electrical join is not at the main power take-off junction,but between two modules), the method shown in FIG. 25 can be used. Themodules may be positioned end on end and then an extra cell 251 can beplaced over the discontinuity to create an electrical connection betweenthe modules while also visually concealing the physical join line forimproved aesthetics.

The BIPV system may incorporate one or more “dummy” cells at variouslocations across the surface of the roof. In a suitable embodiment, thedummy cells will look identical to the rest of the PV cells but willhave no functionality. Because the dummy cell is not active, it can becut to fit the shape/space required and can be penetrated safely ifnecessary. As shown in FIG. 30, two “dummy” modules 301 are positionedin a lapping arrangement with a cutout for a pipe 302 emerging from thebuilding surface. BIPV modules 283 are shown on either side of the“dummy module. In addition, dummy cells may be positioned at the ends ofthe building surface or may be positioned at predetermined locations toprovide for the installation of various building features (satellitereceivers, antennas, pipes, etc.). One advantage of the dummy cells isthat they age identically to the rest of the PV cells and therefore theentire roof surface maintains consistent aesthetic features over time.In some embodiments, the dummy cells may be scribed with markings thatindicate that these cells can be safely penetrated, e.g., for theinstallation of hardware or for fire safety.

The modules may be suitably joined by an overlapping module (forweatherproofing) or an adhesive pad which extends across the join andcontacts the underside surfaces of both modules. It may also benecessary to add a similar adhesive pad to the top side surfaces, or tosmear the reverse side of the joining cell with an adhesive paste tosecure the join.

While the PV cells could simply be placed on any top surface of amodule, in some embodiments the module is formed with a number of relieffeatures on its upper surface to locate and register the PV cells. Thesecan be more clearly seen in FIG. 26A. There are recessed panels orpockets 261 in the cell bearing portion of the shingle modules whichlocate each individual cell, and these are separated by raised orrecessed channels 262. The channels create the impression of “tiled”roofing, and generally add to the aesthetics of the product. Regions atthe top and bottom of the channels 263 provide space for the bus stripsto pass through between each pocket. It may be desirable that theseregions are less raised or lowered than the other parts of the channelso that the bus strip does not have to be bent excessively when it isadhered to the contours of the module substrate.

The exposed portion of the solar cell carrying module may be profiledwith two (or more) rows of pocketing so as to accommodate two (or more)rows of solar cells upon a single module. In such a case there willprovision to locate a set of bus strips for each row, or the profilingmay provide for the location of a shared bus strip(s) to be positionedbetween the rows.

The modules may be molded to accommodate various components of thephotovoltaic system. For example, as shown in FIG. 26B, the uppersurface of the underlapping region may include channels 264 configuredto receive cables or wires of the photovoltaic array. Moreover, theupper surface of the underlapping region may also include formedcavities 265 configured to receive junction boxes 266, printed circuitboards (PCB), communication devices, cables, wires, buses, components,cells, or diodes, and the like of the photovoltaic array. Thus, themodules may contain all of the hardware and software required to connectand regulate the PV cells. Because there are no penetrations between thetwo overlapping modules, the assembly can be completely waterproofed.Furthermore, the upper surface of the exposed region may containscribings or markings, such as an impression or line corresponding tothe molded cavities, thus informing an installer or repair person thatvarious components are located in the space below. The upper surface ofthe underlapping region may also include formed markings 267 to indicatethe correct location of wires and Tee connections for wires, that arelocated in the pathway for airflow 181 underneath the underside of theunderlapping region.

With the modules installed as shown in FIG. 23 most of cell bearingportion of the module is exposed while the rest of the module, includingthe fixing region and fastening means is completely covered byneighbouring modules. This enables maximum power generation but stillprovides some degree of protection for the fastenings to reduce theirrate of degradation and corrosion. The upper electrical bus strip isalso protected by the front edge of the overlapping panel for bothweather and aesthetic reasons. Furthermore, because there are nopenetrations that traverse the entire thickness of the roofing material,this product overcomes the limitations of existing solar products, whichpenetrate the roof membrane with bolts, screws, or nails that must becaulked and can leak. Wires 231 can also run between the bottom of themodule and the weatherproof underlay without penetrating the underlay(as shown in FIG. 23).

The process by which the solar version of the roofing product can becontinuously manufactured is shown in FIG. 27. The first, second andthird steps of preparing, presenting and forming the module are the sameas those described previously, however the fourth step 271 is theapplication of the solar array and the optional fifth step 272 is theapplication of a laminate layer over the solar cells which may havebonding between layers or adhesive layers between them.

Once the module has been formed the PV cells can be deposited on top insuch a way as to be located by the relief features on the upper surface.FIG. 27 shows the PV cells being fed onto the substrate from acontinuous roll feed. In this case the upper and lower bus bars wouldneed to be associated with the cells in a prior step to form the roll.Another option is to deposit the cells individually into the pocketedrelief features of the substrate and to subsequently apply the bus bars(possibly separated by a spacing web) from a separate roll feed. Yetanother option is to feed the bus bars onto the substrate and thenoverlay the solar cells.

An optional step is to apply a transparent laminate 273 to protect thecells. It is convenient to pre-form (also by continuous moulding 274)and apply the laminate in-line, as shown in FIG. 26, so that theaddition of this layer can occur without any increase in the overallproduction cycle time. This can be laminated with some degree ofelectrostatic or adhesive binding to increase adhesion. While a varietyof materials may be suitable as the laminate, a suitable material isfluoropolymer. Ethylene tetrafluoroethylene (ETFE) is an example of anappropriate fluoropolymer, but other polymers able to remain opticallytransparent may also be used. The fluoropolymer creates an essentially“self cleaning” top surface so that performance of the PV cells is notinhibited by deposits of dirt and debris. Fluoropolymer is also verystable in ultraviolet light and usually retains its light transmittingcapacity for longer than glass, which is another commonly used materialin PV applications. It is preferable to choose a material which would beable to maintain light transmission during long periods (approximately10-25 years) of environmental exposure. The laminate is applied alsoover region 117 to cover parts of the panel which are not directlyexposed to light but which will receive reflected light. This laminatealso gives superior durability to the exposed outer area of the paneland may be used even without PV cells to provide greater long termdurability.

In another aspect, the present invention provides a building integratedphotovoltaic system which allows combined solar, ambient andsolar-generated heat to be collected and directed away from a buildingsurface and optionally used elsewhere. For instance, the photovoltaiccells of the energy generating module could heat up during operation. Aswell as potentially causing the interior of the building to heat up as aresult, the cells will also perform less efficiently as they growhotter. A further issue is that the material around the cells will tendto expand due to the heat and this can generate stresses and/or movementthat may eventually lead to product failure. Therefore, there is anadded advantage in combining the features of the BIPV product with thoseof the thermal product, and using the hybrid module as part of a systemwhich generates electrical energy while also allowing heat energy to betransferred away from the solar cells, recovered, and put to use asdesired. FIG. 28 shows a building on which the non-energy harvestingproduct 281, the thermal product 282 and the BIPV product 283 have allbeen installed at different regions of the same building according toenergy and cooling requirements.

The present disclosure is not to be limited in terms of the particularembodiments described in this application. Many modifications andvariations can be made without departing from its spirit and scope, aswill be apparent to those skilled in the art. Functionally equivalentmethods and apparatuses within the scope of the disclosure, in additionto those enumerated herein, will be apparent to those skilled in the artfrom the foregoing descriptions. Such modifications and variations areintended to fall within the scope of the appended claims. The presentdisclosure is to be limited only by the terms of the appended claims,along with the full scope of equivalents to which such claims areentitled. It is to be understood that this disclosure is not limited toparticular methods or systems, which can, of course, vary. It is also tobe understood that the terminology used herein is for the purpose ofdescribing particular embodiments only, and is not intended to belimiting.

In addition, where features or aspects of the disclosure are describedin terms of Markush groups, those skilled in the art will recognize thatthe disclosure is also thereby described in terms of any individualmember or subgroup of members of the Markush group.

As will be understood by one skilled in the art, for any and allpurposes, particularly in terms of providing a written description, allranges disclosed herein also encompass any and all possible sub-rangesand combinations of sub-ranges thereof. Any listed range can be easilyrecognized as sufficiently describing and enabling the same range beingbroken down into at least equal halves, thirds, quarters, fifths,tenths, etc. As a non-limiting example, each range discussed herein canbe readily broken down into a lower third, middle third and upper third,etc. As will also be understood by one skilled in the art all languagesuch as “up to,” “at least,” “greater than,” “less than,” and the likeinclude the number recited and refer to ranges which can be subsequentlybroken down into sub-ranges as discussed above. Finally, as will beunderstood by one skilled in the art, a range includes each individualmember. Thus, for example, a group having 1-3 units refers to groupshaving 1, 2, or 3 units. Similarly, a group having 1-5 units refers togroups having 1, 2, 3, 4, or 5 units, and so forth.

All references cited herein are incorporated by reference in theirentireties and for all purposes to the same extent as if each individualpublication, patent, or patent application was specifically andindividually incorporated by reference in its entirety for all purposes.

The invention claimed is:
 1. A roofing, cladding, or siding modulecomprising: an underlapping region and an exposed region, wherein theunderlapping region is adapted to be substantially covered by theexposed region of an adjacent module when installed on a buildingsurface; and an outer surface and an under surface, wherein the undersurface of the underlapping region is profiled to define a pathway forair flow between the module and the building surface; wherein theprofile of the under surface of the underlapping region is patterned ina manner to (A) create turbulence in the air flow, or (B) increase thesurface area of the module in contact with the passing air flow comparedto a module lacking such a surface pattern, or both (A) and (B); whereinthe profile of the under surface of the underlapping region comprises aplurality of projections extending from said under surface to the actualor a notional plane of the building surface when installed, such thatthe projections create a tortuous pathway between the module and theactual or the notional plane of the building surface; wherein theplurality of projections at least in part define the profile of theunder surface of the underlapping region and are arranged to form thepattern thereon; wherein at least one of said plurality of projectionsis defined by a recess in the outer surface of the underlapping region,said recess configured as a fixing region for receipt of a fastener forsecuring said module to the building surface; wherein the entirety or atleast a substantial part of the under surface of the underlapping regionis patterned; and wherein the under surface of the exposed region isdevoid of projections.
 2. The module of claim 1, wherein the outersurface of the exposed region comprises a photovoltaic cell or device.3. The module of claim 2, wherein a solar radiation transmissible filmis overlaid upon the photovoltaic cell.
 4. The module of claim 1,wherein the module is moulded by thermoforming, pressing or other methodof forming, either continuously or discontinuously, wood, metal,concrete, resins, glass, clay, or composites.
 5. The module of claim 1,comprising a plurality of formed surfaces moulded from one or morepolymeric materials, wherein each of the formed surfaces comprise threedimensional surface features, and wherein the formed surfaces are joinedwithout weld lines or injection moulding points.
 6. The module of claim5, wherein each formed surface is a moulded segment along the length ofthe module.
 7. The module of claim 5, wherein each formed surfacecomprises an underlapping region and an exposed region, wherein theunderlapping region is adapted to be substantially covered by theexposed region of an adjacent module when installed on a buildingsurface.
 8. The module of claim 1, wherein the outer surface of theexposed region comprises surface ornamentation.
 9. The module of claim8, wherein the surface ornamentation resembles asphalt shingles, slate,wooden shakes, or concrete tiles.
 10. The module of claim 1, wherein themodule is moulded from one or more polymeric materials.
 11. The moduleof claim 1, wherein the module is manufactured by a continuous formingprocess.
 12. A roofing, cladding, or siding assembly comprising aplurality of partially-overlapping modules that substantially covers abuilding surface, wherein each module comprises the module of claim 1.13. The assembly of claim 12, wherein one or more of the modulescomprises a photovoltaic cell or device.
 14. A system for removing orrecovering thermal energy from a building surface, the system comprisinga building surface; a roofing, cladding, or siding assembly comprising aplurality of partially-overlapping modules that substantially covers thebuilding surface, wherein each module comprises the module of claim 1;and a fan adapted to induce the air flow.
 15. A system for generatingelectricity and recovering or removing thermal energy from a buildingsurface, the system comprising a building surface; a roofing, cladding,or siding assembly comprising a plurality of the modules of claim 1, andwherein the outer surface of the exposed region comprises one or morephotovoltaic cells.
 16. The system of claim 14 further comprising a ventfor exhausting the air flow.
 17. The system of claim 14 furthercomprising a heat exchanger adapted to receive the air flow.
 18. Thesystem of claim 14, wherein the air flow is induced by a fan.
 19. Thesystem of claim 14, further comprising an air filter located at the airinlet to stop foreign objects entering the airway cavity.
 20. A methodfor removing or recovering thermal energy from a building surface, themethod comprising inducing an air flow to pass through an air passagebetween a building surface and an under surface of a plurality ofpartially-overlapping modules that substantially cover the buildingsurface; wherein each module comprises the module of claim
 1. 21. Amethod for simultaneously generating electricity and recovering thermalenergy from a building surface, the method comprising inducing an airflow to pass through an air passage between a building surface and anunder surface of a plurality of partially-overlapping modules thatsubstantially cover the building surface; and collecting electricalenergy from one or more photovoltaic cells present on an exposed surfaceof the modules; wherein each module comprises the module of claim
 1. 22.A method of manufacture of a roofing, cladding, or siding module, themethod comprising: providing to a continuous forming machine a feedmaterial able to assume and retain a form after being moulded between afirst forming surface and a second forming surface; allowing theformation to take place as such surfaces are advanced in the samedirection; wherein the output is a roofing, cladding, or siding modulecomprising: an underlapping region and an exposed region, wherein theunderlapping region is adapted to be substantially covered by theexposed region of an adjacent module when installed on a buildingsurface; and an outer surface and an under surface, wherein the undersurface of the underlapping region is profiled to define a pathway forair flow between the module and the building surface.
 23. The system ofclaim 14, wherein a pathway for air flow is defined between the undersurface of the plurality of partially-overlapping modules and thebuilding surface upon which said modules are located or to be attached.24. The system of claim 23, wherein the pathway for the air flow allowsfor the flow of air in directions both substantially lateral andsubstantially transverse with respect to the building surface.
 25. Thesystem of claim 23, wherein the pathway for the air flow is a continuouspathway.
 26. The system of claim 23, wherein the building surface is asubstantially continuous planar surface.
 27. The system of claim 23,wherein the plurality of partially-overlapping modules and the buildingsurface define a cavity for air flow bounded on one side by an undersurface of said modules and the building surface upon which said modulesare located on the other side.
 28. The system of claim 15, wherein apathway for air flow is defined between the under surface of theplurality of partially-overlapping modules and the building surface uponwhich said modules are located or to be attached.
 29. The system ofclaim 28, wherein the pathway for air flow allows for the flow of air indirections both substantially lateral and substantially transverse withrespect to the building surface.
 30. The system of claim 28, wherein thepathway for the air flow is a continuous pathway.
 31. The system ofclaim 28, wherein the building surface is a substantially continuousplanar surface.
 32. The system of claim 28, wherein the plurality ofpartially-overlapping modules and the building surface define a cavityfor air flow bounded on one side by an under surface of said modules andthe building surface upon which said modules are located on the otherside.
 33. The system of claim 28, wherein the air flow pathway is acontinuous air flow pathway.
 34. A system comprising: a buildingsurface; a roofing, cladding, or siding assembly comprising a pluralityof partially-overlapping modules that substantially covers the buildingsurface, wherein each module comprises the module of claim 1; andwherein a pathway for air flow is defined between the under surface ofthe plurality of partially-overlapping modules and the building surfaceupon which said modules are located or to be attached.
 35. The system ofclaim 34, wherein the pathway for air flow allows for the flow of air indirections both substantially lateral and substantially transverse withrespect to the building surface.
 36. The system of claim 34, wherein thepathway for the air flow is a continuous pathway.
 37. The system ofclaim 34, wherein the building surface is a substantially continuousplanar surface.
 38. The system of claim 34, wherein the plurality ofpartially-overlapping modules and the building surface define a cavityfor air flow bounded on one side by an under surface of said modules andthe building surface upon which said modules are located on the otherside.
 39. The system of claim 34, wherein the air flow pathway is acontinuous air flow pathway.
 40. The assembly of claim 12, wherein theassembly is to be located or attached to a substantially continuousbuilding surface.
 41. The module of claim 1, wherein the plurality ofprojections provide an even airflow across the entire airway space.